Quality Control Built on Engineering, Data & 18+ Years of Production

# The QC System Behind 2,800+ Plush SKUs and 2000+ Shipments Every Year

Quality at Delsney is not defined by “checking products.” It is engineered across every production stage—from fabric selection and embroidery digitizing to needle control, stuffing density calibration, and final metal detection.

With 2,800+ plush SKUs developed, a 98% sample-to-mass accuracy rate, and products shipped to 86+ countries, Delsney maintains a QC structure built on measurable checkpoints and documented manufacturing discipline.

Each project is governed by:

Structured QC plans
Pre-production risk assessment
Testing protocol for fabrics & accessories
Operator-level control sheets
Daily defect pattern analysis
International safety compliance (EN71, ASTM F963, CPSIA)

QC at Delsney is engineered to prevent issues—not just detect them.

Our Multi-Layer QC Architecture

From Material Verification to Final AQL Inspection

Delsney’s QC system covers 6 independent but synchronized layers—each designed to eliminate risks early and document every critical step.

1. Material & Fabric QC

Fiber composition testing
Colorfastness testing
Shrinkage test (pre-wash)
Hand-feel consistency control
Accessory QC (eyes, noses, zippers, sequins)

Outcome: Only verified materials enter production.

2. Pre-Production QC

Golden sample verification
Sewing pattern check
Embroidery/printing accuracy
Stuffing density matrix
Seam strength pre-test

Outcome: Prevents issues from spreading across entire batches.

3. In-Line QC Control

QC staff placed along each sewing line inspect:

Seam symmetry
Thread tension
Position accuracy
Logo & accessory alignment
Shape consistency

Outcome: Defects are caught before moving forward.

4. End-Line QC

Full-unit inspection
Deformation check
Measurement verification
Hand-feel & softness check
Safety stitching reinforcement

Outcome: Ensures each unit meets the approved Golden Sample.

5. Metal Detection + Needle Control

Every plush item passes needle detection using industrial-grade machines. Broken needle logs are strictly maintained and verified daily.

Outcome: Zero metal contamination incidents in 18+ years.

6. Final AQL Inspection

AQL 0/2.5/4.0 based on client requirement
Carton drop test
Packaging QC
Label accuracy check

Outcome: Batch approved for shipment.

Material & Fabric Quality Verification

Premium Plush Starts With Scientific Fabric Testing

Before any plush prototype is produced, all materials undergo technical analysis by Delsney’s QC and sourcing team.

Material control prevents the top three plush manufacturing risks:

Incorrect softness or GSM
Color fading or transfer
Fabric deformation during stuffing

Fabric Testing Protocol

1. GSM Weight Check (±3% Tolerance)

Ensures fabric matches the softness and density required for curves, shapes and stuffing balance.

2. Colorfastness Testing

Testing includes:

Dry rub
Wet rub
Washing simulation Prevents color bleeding when the plush is handled or cleaned.

3. Shrinkage & Deformation Testing

Performed before cutting patterns to ensure mass-production accuracy.

4. Fiber Safety Testing

Materials must comply with:

EN71 Part 1/2/3
ASTM F963
CPSIA lead limits

5. Accessory QC

Eyes, noses, and small pieces undergo:

Pull tests
Age-grade safety checks
Sharp edge verification

Golden Sample Engineering & Approval

The Technical Blueprint That Controls 100% of Mass Production Accuracy

The Golden Sample is the central engineering reference for all plush production at Delsney. It is not just a visual approval item—it is a technical blueprint containing all measurement values, seam tolerances, stitching placements, fabric combinations, stuffing density levels and accessory specifications.

Across 2,800+ plush SKUs, Delsney maintains an average 98% consistency between Golden Samples and mass-production units.

Golden Sample Engineering Includes

1. Full Measurement Mapping (±0.5–1.0 cm Tolerance)

Every dimension is recorded, including:

Body length
Width & depth
Ear / limb positioning
Eye & nose alignment
Accessory placement

QC uses digital calipers and laser horizontal tools for accuracy.

2. Stitching Path Documentation

Each seam is labeled with:

Stitch density (SPM)
Curve radius
Reinforcement points
Inside-out turning areas
Hidden-stitch positions

This prevents size distortion and ensures structural durability.

3. Embroidery File Calibration

Embroidery digitizing files are matched 1:1 with sample output. QC checks thread thickness, density, sharp angle accuracy, border clarity and color contrast.

4. Stuffing Density Matrix

Different body sections require different filling densities. For example:

Head: 115–130 g
Body: 150–180 g
Limbs: 55–75 g

These values ensure balanced shape and prevent deformation.

5. Accessory Engineering

Eyes, clothing, accessories, magnets, Velcro, sequins and zippers are approved with:

Pull tests
Stability tests
Overlock stitching verification

Once approved, the Golden Sample is stored digitally and physically. Every production line uses it as the absolute reference, guaranteeing visual and structural consistency across thousands of units.

Sewing & Construction Quality Control

Sewing is the core of plush manufacturing. Even the best materials fail if the construction is weak or inconsistent.

Delsney maintains a dedicated sewing QC team positioned along each line to verify structural accuracy, reduce shape distortion, and ensure compliance with Golden Sample data.

Sewing QC Includes

1. Stitch Density Control (6–8 Stitches per cm)

QC checks stitch count and spacing to ensure:

Seam durability
Balanced tension
Avoidance of puckering
Clean curve shapes

2. Symmetry Verification

Left and right limbs, ears, wings, and facial elements are compared with:

Layered transparency sheets
Digital symmetry markers
Tolerance references

This prevents shape imbalance.

3. Curve & Corner Accuracy

QC verifies smooth curvature and clean corner turning—critical for character-based plush toys and licensed IP products.

4. Inner Seam Trimming & Hidden Stitch QC

Hidden stitches must be invisible and structurally strong. QC verifies proper trimming to avoid bulges after stuffing.

5. Stress-Point Reinforcement (Double Stitch Zones)

High-stress areas such as neck joints, wing joints, and tail/limb attachments receive reinforced stitching to prevent tearing.

6. Sewing Machine Calibration

Technicians adjust:

Thread tension
Needle size matching fabric
Oil-free operation for light-colored fabrics
SPM (stitches per minute) to maintain consistency

Even with large-volume production (up to 25,000 units per batch), Delsney maintains a stable shape, strong structure and uniform stitching quality across every line.

Embroidery & Printing Quality Control

High-Resolution Details for Characters, Textures & Brand Elements

Many plush products include detailed embroidery or printed elements such as:

Eyes
Logos
Textures
Facial features
Graphics
Patterns

For IP-driven and collectible plush, accuracy is critical. Delsney’s embroidery QC team ensures pixel-level fidelity between artwork files and physical output.

Embroidery QC Protocol

1. Thread Density Calibration

Density adjusted to avoid:

Gaps
Thread pull
Overdensity causing stiffness

Based on artwork complexity.

2. Color Matching Under Standard Light Conditions

QC evaluates colors under D65 and TL84 lighting to ensure stability across production.

3. Edge Sharpness Verification

Sharp edges around eyes, nose, eyebrows and logos must match the approved Golden Sample.

4. Embroidery Placement Accuracy (±1–2 mm)

Digital templates ensure consistent left-right placement.

Printing QC Protocol

For heat transfer or sublimation printing on plush accessories:

1. DPI Pattern Check

Ensures crisp artwork without pixelation.

2. Alignment Control

Printing lines must match cut patterns accurately.

3. Color Stability Test

Heat resistance, rub resistance and washing resistance are checked before approval.

All embroidery and printed elements on the plush remain clean, sharp and consistent—suitable for retail and licensed product standards.

Stuffing Density & Shape Stability QC

Stuffing is the soul of plush manufacturing. It determines:

Softness
Shape stability
Balance
Symmetry
Touch quality
Long-term deformation resistance

Delsney uses a quantitative filling system rather than “experience-based” filling.

Across 2,800+ plush models, Delsney maintains 95% shape stability after 72-hour compression testing, a key metric in retail-grade plush manufacturing.

Weight-Controlled Filling (±2–5 g Tolerance)

Every section of the plush has assigned filling weight:

Head: 115–130 g
Body: 150–180 g
Limbs: 55–75 g
Tail/ears: 10–25 g

Digital scales ensure high accuracy.

Multi-Zone Density Mapping

Delsney develops density maps for complex characters to avoid:

Overstuffing (causing hardness)
Understuffing (causing sagging)
Asymmetric proportions

Rebound & Elasticity Testing

QC performs:

Compression tests
24-hour deformation tests
Drop tests

Ensures long-term shape retention, crucial for premium retail plush.

Filling Fiber QC

Filling fibers undergo:

Cleanliness check
Odor-free requirement
Fiber length consistency
EN71/ASTM safety compliance

Even after extended compression, Delsney plush toys maintain shape and softness with minimal deformation—ideal for IP merchandise, retail chains, and collectible plush.

Safety & International Compliance Testing

EN71, ASTM F963, CPSIA — Every Product Built for Global Market Regulations

Safety is non-negotiable in plush manufacturing. Delsney manufactures for clients in Europe、USA、Japan、Korea、Australia and maintains compliance with the world’s strictest toy regulations.

QC and engineering teams prepare all documents required for:

Retail audits
Licensing approvals
Amazon / Walmart compliance
Customs clearance

Global Safety Standards Delsney Supports

EN71 (Europe)

Part 1: Physical & mechanical tests
Part 2: Flame retardancy
Part 3: Heavy metal migration

ASTM F963 (USA)

Mechanical testing
Stuffing material safety
Small parts testing

CPSIA (USA)

Lead limit
Phthalates restrictions

REACH (EU)

Chemical safety compliance

AS/NZS (Australia)

Mechanical & flammability requirements

ST Mark (Japan)

Strict mechanical safety tests

Safety Testing Conducted During QC

1. Pull Test (90N Standard)

Ensuring eyes, noses, and accessories cannot detach.

2. Torque Test

Guarantee that twisting elements stay secure.

3. Tension & Seam Strength Test

Prevents tearing under normal play.

4. Sharp-Edge & Sharp-Point Test

Ensures no hidden hazards inside or outside the plush.

5. Metal Detection

100% of plush toys pass industrial-level metal detection.

Every plush item produced by Delsney meets international toy safety requirements, backed by clear documentation and verifiable testing records.

In-Line QC & Final Inspection Protocols

Every Plush Inspected at Multiple Checkpoints Before Leaving the Factory

Delsney uses a multi-checkpoint QC system to catch issues early and ensure final consistency. With 2000+ shipments annually, maintaining predictable output is essential.

In-Line QC & Final Inspection Protocols

QC staff are positioned along production lines and perform checks on every batch of semi-finished units.

In-Line QC Includes

Seam accuracy
Symmetry consistency
Embroidery alignment
Filling density
Hand-feel check
Accessory stability
Facial expression matching Golden Sample

Any deviations are stopped immediately, preventing mass errors.

End-Line QC (After Full Assembly)

Once plush units are fully assembled:

End-Line QC Includes

Full visual inspection
Deformation test
Loose thread trimming
Measurement verification
Softness & rebound test
Golden Sample comparison

End-line QC maintains Delsney’s 98% mass-production accuracy.

Final AQL Inspection Before Shipment

AQL Standards:

AQL 0 (Critical)
AQL 2.5 (Major)
AQL 4.0 (Minor)

QC performs carton-by-carton sampling:

Final QC Includes

Packaging inspection
Label accuracy
Barcode readability
Carton strength
Carton drop test
Moisture control checks

No shipment leaves Delsney without passing full AQL inspection, ensuring each order arrives in retail-ready condition.

Metal Detection & Needle Control Management

Industrial-Grade Safety Systems Ensuring Zero Metal Contamination for 18+ Years

Metal contamination is one of the most strictly controlled safety risks in global plush manufacturing. Delsney enforces a zero-tolerance metal management system, combining strict needle logs, machine-level detection and a dual-check protocol.

Across 18+ years and thousands of batches delivered, Delsney has maintained a 0 incident record with retailers, licensing companies and corporate merchandise brands.

Needle Control System

1. Daily Needle Log (Registered & Signed)

Every needle is registered before use, including:

Needle ID
Operator name
Machine number
Start time & end time
Reason for replacement

A supervisor signs each log.

2. Broken Needle Procedure

If a needle breaks:

All fragments must be accounted for
The machine is paused immediately
QC re-inspects all surrounding units
Broken needle fragments are stored in a sealed container
Supervisor signature is required to resume work

This ensures no metal fragments enter the plush body.

Metal Detection Process

1. 100% Unit Metal Scan

Every plush product passes through an industrial-level metal detector set at high sensitivity.

2. Two-Pass Detection

Each plush is scanned twice:

Before packaging
After packaging

3. Batch-Level Traceability

Each approved batch has a metal-detection certificate tied to:

Order number
Production line
Operator
Date and time

Delsney ensures each plush toy is fully free of metal contamination—meeting EN71, ASTM F963 and CPSIA safety requirements for global retail markets.

Packaging Quality Control & Carton Safety Testing

Ensuring Every Plush Survives Transport, Storage & Retail Handling Without Damage

Packaging directly impacts product safety, carton strength and final retail presentation. Delsney integrates packaging QC into every production cycle to achieve zero-damage shipments, especially for large-volume ocean freight.

Primary Packaging QC

1. Polybag QC

Thickness control (0.03–0.05 mm)
Seal integrity inspection
Warning label accuracy
Air-vent hole testing

2. Barcode & Label Verification

UPC/EAN validation
Smudge-proof tests
Placement accuracy (±2 mm)

3. Accessory Protection

Hats, clothing, wings or fragile decorative elements are supported with cardboard or tissue to prevent crushing.

Carton QC

1. Carton Strength Test

Using ECT 44–48 corrugated material for export-grade strength.

2. Carton Drop Test

Performed from 80–120 cm height on 8 angles:

1 corner
3 edges
6 surfaces

Ensures plush arrives in perfect condition worldwide.

3. Moisture Content Control

Cartons are checked with a moisture meter to ensure < 12% humidity before loading containers — preventing mold growth during long shipping routes.

4. Packing Density Optimization

Delsney engineers packing layouts to avoid:

Over-compression
Shape deformation
Excess wasted space
Shipping cost inflation

With optimized packaging engineering and carton QC, Delsney maintains a less than 0.3% transit-related defect rate across 2000+ shipments annually.

Frequently Asked Questions

Clear, Practical Answers Based on Delsney’s Real QC, Production & Compliance Systems

Q1: How does Delsney ensure sample accuracy matches mass production?

Sample accuracy is controlled through a strict Golden Sample engineering process with full measurement mapping, stitch-density documentation, embroidery calibration and stuffing-density matrices. The approved Golden Sample is digitally archived and physically sealed, then used on every production line as the single reference source. With this system, Delsney maintains a 98% consistency rate across thousands of units—even for complex character plush with multiple colorways or accessories.

Q2: What QC checkpoints occur before mass production begins?

Before production starts, Delsney performs material testing (GSM, colorfastness, shrinkage), accessory strength tests, pre-production embroidery checks, pattern verification and stuffing trials. Engineering also completes a risk assessment to identify issues that may arise during high-volume output. Only after these steps are verified does the project move into formal line scheduling.

Q3: How does Delsney control sewing quality across high-volume orders?

Sewing quality is managed through multi-stage QC: in-line inspectors verify stitch density, seam durability, curve precision and symmetry at each workstation. High-stress areas receive reinforcement stitches, and technicians adjust tension, SPM and needle type based on fabric thickness. With these controls, Delsney prevents seam distortion and maintains consistent shape even in 25,000-unit batches.

Q4: How is filling softness and shape stability guaranteed?

Each plush component has a precise filling weight range measured in grams, with tolerances as low as ±2–5 grams. QC performs multi-zone density mapping, compression tests and rebound evaluations. Filling fibers are also tested for cleanliness, odor, elasticity and compliance. This engineered approach ensures softness, balanced weight and long-term shape retention.

Q5: What safety tests are used to meet international toy regulations?

Delsney complies with EN71, ASTM F963, CPSIA, REACH and other global standards. Safety tests include pull tests, torque tests, tension tests, seam-strength tests, sharp-edge inspection, color migration analysis and 100% metal detection. Compliance documents are provided to support retail audits, customs clearance and licensing approvals.

Q6: What is the needle-control system, and why is it important?

Needle control prevents metal fragments from entering plush toys. Delsney registers each needle before use, logs every replacement, stores broken needle fragments in sealed containers and performs re-inspection on affected units. Combined with 100% metal detection on all finished products, Delsney has maintained a zero-incident safety record for over 18 years.

Q7: How does Delsney ensure consistency across left-right symmetrical parts?

QC uses layered transparency sheets, digital alignment tools and tolerance markers to compare left vs. right limbs, ears, wings and facial details. Symmetry is checked during in-line and end-line QC stages. This prevents crooked features, uneven shapes and misalignment—common issues in lower-skilled factories.

Q8: How is embroidery and printing accuracy maintained?

Embroidery accuracy is controlled through thread-density calibration, color matching under D65/TL84 light, edge sharpness checks and ±1–2 mm placement verification. For printed elements, QC verifies DPI clarity, heat-transfer alignment and rubbing resistance. All outputs are compared to the Golden Sample to ensure identical appearance and color performance.

Q9: What steps occur during final inspection before shipment?

Final AQL inspection covers visual appearance, measurements, stitching integrity, shape consistency, accessory firmness, barcode readability and packaging safety. QC also performs carton-drop tests, polybag seal checks, humidity measurements and outer carton strength tests. Only batches meeting the assigned AQL standard (0/2.5/4.0) are cleared for shipment.

Q10: How does Delsney maintain low defect rates across large orders?

Delsney maintains a defect rate far below industry averages through multi-layer QC, real-time defect pattern analysis, daily operator feedback loops, precise material control, documented sewing procedures and strict end-line inspection. Production data is reviewed each morning by engineering, QC and production teams to continuously refine processes. This system provides predictable quality even for 20,000–50,000-unit seasonal programs.

Start Your Project With a Proven QC System

A strong QC system is not built overnight. Delsney’s quality control framework comes from 18+ years of production, 2,800+ developed plush SKUs, global compliance expertise, and a continuous loop of improvement based on real defect analysis and engineering data.

For brand owners, IP licensors, retailers and e-commerce teams who need reliable plush manufacturing, a factory’s QC system determines:

Consistency across large quantities
Retail compliance success
Product safety
Long-term customer satisfaction
Total project reliability

Delsney provides a quality system that is measurable, transparent and engineered—not guesswork.